U.S. patent number 5,425,823 [Application Number 07/575,217] was granted by the patent office on 1995-06-20 for combination label printer and application device.
This patent grant is currently assigned to B.C.E. Technologies. Invention is credited to James Woodside, III.
United States Patent |
5,425,823 |
Woodside, III |
June 20, 1995 |
**Please see images for:
( Certificate of Correction ) ** |
Combination label printer and application device
Abstract
A combined label printer and application device is provided for
labeling a plurality of individual product units with customized
labels. The individual product units are conveyed through a data
determining mechanism, such as a checkweigher or electric eye in
order to identify data to be imprinted on the label. The
information is conveyed to a microprocessor which converts the data
into commands for a label printer. The printer in turn prints
either alpha-numeric indicia, bar codes or other desired visual
indicia on the label. The movement of the individual product units
is coordinated with a corresponding label, and the label is applied
to the product unit by means of a combined vacuum and air jet head.
The individual labels, in a preferred embodiment, are coated with
pressure sensitive adhesive, and are fixed on rolls to releasible
backing strip. The individual labels are stripped from the backing
strip and held temporarily on a vacuum head until the desired
product unit is located below the head. Air jets then blow the
label onto the product unit with sufficient force to cause adhesion
of the label to the product.
Inventors: |
Woodside, III; James (St.
Petersburg, FL) |
Assignee: |
B.C.E. Technologies (Tampa,
FL)
|
Family
ID: |
24299406 |
Appl.
No.: |
07/575,217 |
Filed: |
August 30, 1990 |
Current U.S.
Class: |
156/64; 156/277;
156/285; 156/360; 156/384 |
Current CPC
Class: |
B65C
1/02 (20130101); B65C 9/44 (20130101) |
Current International
Class: |
B65C
1/00 (20060101); B65C 1/02 (20060101); B65C
9/00 (20060101); B65C 9/44 (20060101); B32B
031/00 () |
Field of
Search: |
;156/277,285,64,360,361,362,384,387,542,566 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Simmons; David A.
Assistant Examiner: Sells; J.
Attorney, Agent or Firm: Michael Best & Friedrich
Claims
I claim as my invention:
1. A method of continuously printing and applying individual labels
having visible indicia thereon unique to each product unit:
determining data relevant to said product unit;
communicating said data to a printer;
translating said data into commands for printing a label;
dispensing a plurality of individual labels;
printing visible indicia on each of said labels corresponding to
said data for each of said product units;
coordinating movement of said labels relative to said product units
so that each label is aligned with its corresponding product
unit;
applying each of said labels to its corresponding product unit;
wherein said step of determining data comprises: reading a bar code
on said product unit.
2. A method of continuously printing and applying individual labels
having visible indicia thereon unique to each product unit:
determining data relevant to said product unit;
communicating said data to a printer;
translating said data into commands for printing a label;
dispensing a plurality of individual labels;
printing visible indicia on each of said labels corresponding to
said data for each of said product units;
coordinating movement of said labels relative to said product units
so that each label is aligned with its corresponding product
unit;
applying each of said labels to its corresponding product unit;
wherein said step of determining data comprises: measuring the size
of said product unit.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to labeling equipment in general and
in particular to combination label printers and application
device.
2. Prior Art
Label applicators typically apply labels to articles as the
articles are conveyed past the label applicator. Usually, the
labels are releasably adhered, in a single column, to an elongated
backing strip. The label applicator removes one of the labels from
the backing strip and releasably retains it at a labeling station.
As the article to be labeled nears the removed label, it is applied
to the article. Label applicators of this type are shown, for
example, in U.S. Pat. Nos. 3,093,528, 3,729,362, 4,024,011 and Re.
30,149.
Label applicators of this type, while satisfactory for many
applications, can introduce delay into an assembly or packaging
operation in which labeling must be carried out. For example, label
indexing or advancement; i.e., the removal of a label from a
backing strip and applying it to a suitable retaining means, is
relatively slow while the transfer of a retained label to the
article can be rapidly carried out. Label indexing can be
sufficiently slow so that the labeling function is the slowest
operation on the production line.
Other work operations also involve the repetitive supply of
elements to a work station so that such elements can be affixed,
assembled, laminated, etc., to articles being conveyed through the
work station. In some of the work operations, the repetitive supply
of the elements is the slowest step in the process, and
accordingly, this limits the speed with which the articles can be
conveyed through the work station. Thus, other work operations
involve problems similar to the label application problem described
above.
An additional problem in the high speed labeling of articles is to
provide labels contain unique information for each individual
package, such as weight, product size, a bar code, or a product
identification number. The synchronization of a high speed printer
with a label applying device which can successfully apply the
correct label to the desired product unit has heretofore elluded
the efforts of those in the industry.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a
labeling device which can apply pressure sensitive labels at high
speed to individual product units on a continuous flow basis.
It is an additional object of the present invention to provide such
a device which can print individual labels having unique product
identification data and apply them to the correct product unit on a
continuous flow basis.
It is a further object of the present invention to provide such a
device which is low in cost, easy to operate and easy to
repair.
In accordance with these and other objects of the invention, a
combination label printer and automatic label applying device is
provided for applying the labels to a series of product units. The
device includes a conveyor for continuously conveying a series of
individual product units. A number of different mechanisms may be
utilized for determining data relative to each of the product
units. For example, in one embodiment, a check weigher is provided
for weighing individual boxes of products. Alternatively,
photovoltaic cells may be utilized to measure the length and height
of the product. Similarly, a video camera may be utilized to
determine the type of product contained within the individual
product unit. Again alternatively, a bar code may already be
affixed to the product indicating the product type, and a bar code
reader may be utilized for accessing this information. This
information may then be printed in alpha-numeric form on the label.
Again alternatively, the information may be determined by a
individual operator visually. A high speed printer is then provided
for printing the information onto a series of labels. A
microprocessor coordinates the movement of the labels with the
movement of the product units, so that the appropriate labels align
with each product unit. The labels are then applied to each product
unit. In a preferred embodiment, the labels are applied by means of
a combination vacuum pad, air jet device. Specifically the pressure
sensitive labels are removed from the roll of backing material
individually and held momentarily on a vacuum pad. When the
appropriate product unit is in position for labeling, an air jet
blows the label off the vacuum pad and onto the unit. The force of
the air jet causes the adhesive on the back side of the label to
adhere to the product unit. A take-away conveyor then removes the
product unit from the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the combination label printer
and automatic label applying device of the present invention.
FIG. 2 is a side view of the printer and label applicator portion
of the present invention.
FIG. 3 is a front perspective view of the printer and label
applicator portion of the invention.
FIG. 4 is a sectional view of the applicator portion of the present
invention.
FIG. 5 is a block diagram of the computer board portion of the
present invention.
FIG. 6 is a block diagram of the microprocessor portion of the
present invention configured for a single printer and applicator
station.
FIGS. 7 and 8 are block diagrams of equipment configurations
capable of printing and applying two labels at a time.
FIG. 9 is a flow chart showing the logic utilized in controlling
application of labels to products as they pass along the device of
the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As best shown in FIGS. 1 and 5-8 of the drawings, a combination
label printer and automatic label applying device 10 is shown.
Device 10 is used for applying labels 12 to a series of individual
product units 14a, 14b and 14c. Device 10 includes a conveyor
mechanism 16 which includes a conveyor belt 18, rollers 20, a drive
mechanism 22 (not shown) and an electric motor 24 (not shown) which
drives the drive mechanism 22 which in turn causes the rollers 20
to rotate, thereby advancing conveyor belt 18. The speed of
conveyor belt 18 is controlled by the speed of the electric motor
24.
As further seen in FIGS. 1 and 5-8, a mechanism 26 in the form of a
check weigher is provided for determining data relative to each
product unit 14. In particular, check weigher 26, in a preferred
embodiment comprises a strain gauge loadcell having a standard
range of 6,000 grams or an optional range of 15,000 grams. Electric
motor 24 preferably comprises a standard 1/4 horsepower permanent
magnet motor with variable speed. The speed of conveyor belt 18, in
a preferred embodiment, is 20 to 700 feet per minute. As product
units pass over check weigher 26 each individual product unit is
weighed and the resulting data is stored in microprocessor 28. The
data is conveyed between check weigher 26 and microprocessor 28 by
means of conventional electric wiring 30. Microprocessor 28
converts the electrical signals from check weigher 26 into digital
form which in turn is conveyed to printer 32 through an RS-232-C
interface 34.
In addition to conveying data to printer 32, microprocessor 28 also
coordinates movement of the product units 14 with movement of the
labels 12, so as to align each product unit 14 with its
corresponding label 12. This is accomplished by means of a series
of photovoltaic cells 36 which show the position of each product
unit as it passes along conveyor 16. As a result, microprocessor 28
can calculate when the product unit 14 has arrived under the label
applicator 38. Finally after application of label 12 to the product
unit 14, the product unit 14 is carried from the device by
take-away conveyor 40.
As further shown in FIGS. 1 and 5-8, a control console 42 is
provided for controlling the operation of the device 10. Control
console 42 includes an operator key pad 44 and a display 46. In a
preferred embodiment, menus on a two line/40 character display 46,
provide instructions in English language or abbreviations.
As shown in FIGS. 7 and 8, in the embodiment shown, a pair of
printers 32 and label applicators 38 are provided for printing and
applying labels two at a time. Thus the line speed in a preferred
embodiment is increased to 180 packages per minute. Operation of
the printers 32 and label applicators 38 is controlled by
microprocessor 28 so as to insure proper alignment of the labels 12
with each individual product unit 14. In a preferred embodiment,
product unit 14 is preferably no greater than 12 inches in length,
and 17 inches in width. The height of the product unit is flexible
depending on product stability. As illustrated in FIG. 1, the
height of the product units 14 relative to the printers 32 and
labelers 38 can be controlled by hydraulic or electric jacks 48 and
50.
As shown in FIGS. 5 and 6, microprocessor 28 includes a resident
E-prom (Erasable Programmable Memory) 52 on the computer board 54.
The E-prom 52 has been preprogrammed with a fixed set of imprint
fields and is fed a data signal from an interfaced scaling device
checkweigher 26. The data signal to the E-Prom 52 on the computer
board 54 prompts the computation of "on-demand" human readable and
bar code characters, and the computed data is then downloaded
on-line and in real time to the thermoprinting head 56 by an
interface print head control PC board 58. This data then prompts
the advance of the labels 12.
As illustrated in FIGS. 2 and 4, single label 12 is moved out of
the print head 56 and directly onto the applicator plate 60. The
label 12 is held in place by a constant vacuum pulled via a small
fan motor 62, mounted in the top 64 of the applicator assembly 38.
Mounted inside the lower portion 66 of the applicator housing 68 is
a small manifold 70. This manifold 70 is square in design and has
two primary holding chambers 72 and 74 for in feed compressed air.
Thirty to forty pounds per square inch of compressed air are
constantly fed into the manifold 70. The pressure within the
manifold 70 is regulated by a series of air valves 76 located on
the main base plate 78 of the applicator 38. The air valves 76
adjust the air in flow for various functions. Compressed air is
held in these manifold chambers 72 and 74 and released upon an
electronic signal from a photoelectric or eye sensor 36 located on
the conveyor line 16, which is tripped by the product unit 14 as it
travels down the conveyor 16. The photoelectric eye's electronic
signal then prompts the air valve regulator 80 (not shown) to force
more regulated air into the manifold 72 via the in feed air line
82. As more regulated compressed air is forced into the manifold
chambers 72 and 74, the compressed air already stored in the
manifolds air chambers are forced out. Plastic air jet nozzles 86
are screwed into drilled and tapped holes 88 strategically placed
in the base of the manifold 70 and primary compressed air chambers
72 and 74. The compressed air which is forced out of the manifold
70 is forced out through these air jet nozzles 86, which forces the
regulated compressed air down onto strategic points of the labels.
The downward release of the regulated compressed air blows the
labels 12 down onto the product unit to be labeled in a single
blast action and precisely places the label on the product unit as
it is moving rapidly past the printer applicator 38. The entire
process described can and is repeated 60 to 120 times a minute
depending on the product size, weigh and labeling accuracy
requirements. FIG. 9 illustrates a flow chart of steps
involved.
The air jet nozzles 86 can be plugged, and the air jet nozzles 86
can be screwed into position in a variety of positions in order to
precisely direct the compressed regulated air as it escaped from
the manifold 70, thus increasing the accuracy of the label 12
movement from the applicator plate 60 through mid air and onto the
product unit 14. The entire manifold 70 is mounted inside of the
applicator housing 68, which is secured by two hex bolts 88 and 90
(not shown), which screw into the side of the manifold 70 from the
outside of the applicator housing 68. The two hex screws 88 and 90
also act as adjustments for the manifold's 70 position relative to
the applicator plate 60, which allows for further label dispensing
accuracy settings.
The applicator plate 60 and use of the air valves 76 allows
extremely precise application of labels with an accuracy of plus or
minus 1/8 inch precision from distances as far away as 18
inches.
Turning to FIG. 2 of the drawings, label roll 90 contains a roll of
either blank or preprinted labels 12. Roll 90 may contain up to
5,000 labels based on 2 inch tall labels. From roll 90, labels 12
extend continuously onto guide roller 92 and into printhead
mechanism 32. Printhead mechanism 32 intermittently is applied by
means of electronic control onto print labels 12, so as to print
the desired alpha-numeric, or graphic indicia on each label 12. The
continuous roll of labels is then directed backward along the
bottom 96 of applicator housing 68. Each individual label is
directed from the backing 98 of labels 12 onto the applicator plate
60 as described above. The individual label 12 is then directed
downwardly by the blast of compressed air when the product unit 14
is below the applicator plate 60.
As mentioned above, labels 12 come in preprinted or blank rolls one
inch to 61/2 inches in width. The rolls may be up to 12 inches
maximum diameter on a 3 inch core. Character height of the printing
may be from 0.07 inches and 6 standard alpha-numeric fonts are
available in a preferred embodiment. Bar code density is a minimum
bar width of 0.010 inch, with print width being from 2 to 6.2
inches. Print speed is 3.5 inches per second.
In a preferred embodiment, the device 10 utilizes a thermal printer
32. Specially treated labels, as known in the art, are susceptible
to thermal imprint. Thus by electrostatically applying the desired
pattern using either UPC, Interleaved 2 of 5, Code 39, EAN, or
Codebar technology Symbologies, a wide range of character fonts and
fast print speeds may be accomplished.
The previously mentioned control console 42 preferably has 40
characters and a liquid crystal display 100. The key pad has 48
keys contained within a polycarbonate overlay with four additional
user definable function keys and four standard printer control
keys. In addition a 6 inch by 3/4 inch overlay window may be
provided for operator instruction menus.
In a preferred embodiment, microprocessor 28 has a non-volatile
memory of 16K and interfaces utilizing standard RS-232-C ports with
preferred configuration being TX Data, RX Data, and Signal
Ground.
The software required to convert the data from the check weigher 26
to alpha-numeric or bar code labeling on printer 32 is attached in
the form of micro fiche, and is incorporated herein.
Referring now to FIG. 5, the computer board 54 incorporates
microprocessing unit 100 for executing instructions stored in EPROM
52. The microprocessing unit used in the preferred embodiment is
type Z80-A manufactured by Zilog Corporation. The address, control,
and data signals generated by the microprocessing unit are buffered
by signal buffers 102 and 104, and bi-directional buffers 106,
respectively. The outputs of the buffers are designated as address
bus 108, control bus 110, and data bus 112. The three buses
interface the microprocessing unit to memory and input/output (I/O)
located on computer board 54 and located on other boards within
microprocessor 28. Resident on the computer board are the EPROM
program store 52 of maximum capacity of 32,768 bytes, EPROM
non-volatile data store 114 having a maximum capacity of 16,384
bytes and read-write RAM memory 116 of 2,048 byte capacity. Also
present on the computer board is serial communications interface
118 that is capable of servicing two RS232C serial ports 30 and
120, identified as COM1 and COM2, respectively. In the preferred
embodiment, COM1 is utilized to communicate with check weigher 26
while COM2 is available for communications with other equipment or
with a separate operator console 42. Programmable timer 122
provides serial bit timing clocks for serial interface 118 and a
periodic interrupt signal to microprocessing unit 100 via interrupt
line 124. Input/output device selection signals for serial
interface 118 and timer 122 are generated by local I/O decoder 126.
An additional output of decoder 126 activates system I/O decoder
128. The system I/O decoder outputs sixteen unique I/O enables that
are distributed to other boards within microprocessor 28. These
sixteen lines are identified collectively as the I/O enable bus,
130, and individually as IO-1 through IO-16. Operation of the
computer board is coordinated by clock signals generated by
oscillator 132. Instructions are provided within EPROM 52 to
receive data relative to each product unit, convert the data to
printable indicia and control various peripheral devices to effect
the printing of labels and to coordinate movements of labels and
product units.
Turning to FIG. 6 of the drawings, system buses 108, 110, 112, and
130 are routed from the computer board 54 to control board 58 and
digital I/O board 134. The control board contains the electronics
necessary to interface the printer mechanism 32 and photovoltaic
cells 36 to the computer board 54. The digital I/O board connects
the display module 46 to the system buses and interfaces the
operator keypads 44 and air valves 76 to the computer board. The
control board 58 has two registers that allow operation of the
printer mechanism 32 by software program. The printer data shift
register 136 receives data bytes from data bus 112 when strobed by
I/O enable signal IO-12. The shift register transmits the data to
printhead 36 bitsequentially. The data so transmitted may represent
human readable or machine readable indicia. Printhead and motor
commands are loaded into control latch 138 from the data bus by I/O
enable signal IO-11. After the dot pattern for an entire print line
has been sent to the printhead via shift register 136, a print
command is issued to the printhead and a motor step command is
issued to the stepping motor interface 140. The stepping motor
interface sequences currents through the windings of stepping motor
142 thereby causing the label 12 to advance through the print
mechanism and resulting in the presentation of the next line in
sequence to the printhead. When printing operations are completed,
motor step commands are issued to bring the next label into the
printhead.
Buffer 144 on the control board 58 allows the microprocessing unit
100 to monitor the position of labels within the print mechanism 32
and the position of product units 14a, 14b, and 14c on the conveyor
mechanism 16. Inter-label gaps are detected by photovoltaic cell
146 and operational amplifier 148. The presence of a gap is latched
in inter-label gap detect flip-flop 150. The flip-flop is cleared
by I/O enable signal IO-13. The presence of a product unit at the
check weigher is detected by scale photocell 152 while the presence
of a product unit at applicator 38 is detected by photocell 154.
These signals are read by the microprocessing unit 100 when I/O
enable signal IO-14 is activated. The speed of product units may be
readily determined by the microprocessing unit by measuring the
delay between the appearance of a unit at photocell 152 and its
subsequent appearance at photocell 154. By maintaining a count of
the number of product units between photocells 152 and 154, the
microprocessing unit can coordinate the printing and movement of
labels with the movement of product units so as to ensure the
application of labels to their corresponding product units.
The digital I/O board 134 interfaces the microprocessing unit 100
to the operator keypads 44 and air control valves 76 and provides
connections to the display module 46. Keypad row latch 156, loaded
by IO enable IO-3, drives the row inputs of keypads. The column
outputs of the keypads are read via column buffers 158 and 160 by
activating I/O enables IO-4 and IO-5, respectively. The display
module 46 is enabled onto the data bus by the logical OR
combination of IO-1 and IO-2. Digital output port 162 is clocked by
I/O enables IO-9 and IO-10 to drive the input diode of triac-output
optocoupler 164. It also provides 15 uncommitted output lines. The
triac is connected in series with the AC line voltage source 166
and air control valves 76 such that when the optocoupler is driven
by port 162, the label 12 is blown off of applicator plate 60 onto
the product unit. Buffers 168 and 170, enabled by IO enables IO-15
and IO-16, allow the microprocessing unit to query the settings of
eight pole option switch 172 and eight pole baud rate select switch
174. Buffer 176, enabled by IO-6 and IO-7, provides sixteen
uncommitted input lines. The uncommitted inputs of buffer 176 and
the uncommitted outputs of output port 162 may be utilized to
implement optional features. These features may include control of
electric motor 24 to regulate the speed of conveyer mechanism 16,
thereby coordinating the movement of product units with the
movement of their respective labels and the monitoring of
photocells in conjunction with control of hydraulic or electric
jacks 48 and 50 to determine the size or product number of a
product unit.
In FIG. 7 a pair of printers 32 and label applicators 38 are
configured with two microprocessors 28 to form two printer and
applicator stations, 200 and 202. The microprocessors are used
without their respective keypads 44 and display modules 46. The
stations are controlled by a common operator console 204 via RS232C
serial communications interfaces 206 and 208. The common operator
console is comprised of a computer board 54 with digital I/O board
134, keypads 44, and display module 46. The RS232C interface 30
from check weigher 26 is connected to both stations. Labels may be
printed and applied two at a time with this configuration thus
doubling the line speed.
Other multiple station configurations are possible. In FIG. 8,
station 200 is equipped with a keypad 44 and a display 46 and it
performs printing and the operator interface functions of operator
console 204 of FIG. 7. Station 200 controls station 202 via RS232C
communications while both stations receive product unit information
from check weigher 26 via serial link 30.
The foregoing merely explains and illustrates the invention and the
invention is not limited thereto except insofar as those who have
the disclosure before them are able to make modifications and
variations therein without departing from the scope of the
invention.
* * * * *